DESIGN OF MACHINE ELEMENTS

Nivish George
Threaded Joints: Types

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Cap screws with different heads

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Screw Threads: Terminology

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 Screw Threads: Terminology
Major diameter: The major diameter is the diameter of an imaginary
cylinder that bounds the crest of an external thread (d) or the root of an
internal thread (D) (Also called as nominal diameter)
Minor diameter: The minor diameter is the diameter of an imaginary
cylinder that bounds the roots of an external thread (dc) or the crest of
an internal thread (Dc)
Pitch diameter: The pitch diameter is the diameter of an imaginary
cylinder, the surface of which would pass through the threads at such
points as to make the width of the threads equal to the width of spaces
cut by the surface of the cylinder
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 Screw Threads: Terminology
Pitch, p: It is the distance between two similar points on adjacent
threads measured parallel to the axis of the thread
Lead: It is the distance that the nut moves parallel to the axis of the
screw, when the nut is given one turn
Thread angle: It is the angle between the sides of the thread measured
in an axial plane
Tensile stress area: Tensile strength of the threaded rods is equal to the
tensile strength of the unthreaded rod whose diameter is equal to the
mean of the pitch and the minor diameter. The cross sectional area of
this unthreaded rod is called as tensile stress area

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 Screw Threads: Standards
B.S.W thread: Symmetrical V thread with thread angle 55 deg. Used in
bolts and screwed fastenings

B.A thread: B.S.W threads with fine pitches. Instruments and other
precision works

American national standard thread: Flat crest and roots. General

purpose threads in bolts, nuts and tapped holes

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 Screw Threads: Standards

Unified standard thread: Included angle of 60 deg.

Square thread : High efficiency and are used for power transmission.
Not strong as V threads but offers lesser frictional resistance

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 Screw Threads: Standards
Acme thread: Modification of square thread. Used in screw cutting
lathes, bench vices

Knuckle thread: A modification of square thread with rounded top and

bottom. Necks of glass bottles, large moulded insulators

Buttress thread: Power transmission in one direction. Has the advantage

of square and V thread

Metric thread: Same as B.S.W with an included angle of 55 deg

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 Bolted Joint: Design Procedure
1. Initial stresses due to screwing up forces (Tensile)
𝐹𝑖 = 2805𝑑 (Eqn. 9.1c)

2. Tensile stress due to external forces

𝜋 2
𝐹 = 𝑑1 𝜎𝑇 × 𝑛
4
3. Shear stress
𝐹𝑠 = 𝜋𝑑1 ℎ𝜏 × 𝑛

4. Combined tension and shear stress

1
𝜏𝑚𝑎𝑥 = 𝜎𝑇2 + 4𝜏 2
2
𝜎𝑇 1 Bolt in Tension
𝜎𝑇𝑚𝑎𝑥 = + 𝜎𝑇2 + 4𝜏 2
2 2
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 Problem 3.1
An eye bolt is to be used for lifting a load of 10 kN.
The eye bolt is screwed into the frame of the motor.
The eye bolt has coarse threads. It is made of plain
carbon steel 30C8 (Syt = 400N/mm2) and factor of
safety is 6. Determine the size of the bolt

Problem 3.2
Two plates are fastened by means of
two bolts as shown in Figure. The
bolts are made of plain carbon steel
30C8 (Syt = 400N/mm2) and the factor
of safety is 5. Determine the size of
the bolts, if P = 5kN
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Eccentric load acting in the plane containing the bolts
𝐴1 𝑥1 + 𝐴2 𝑥2 + 𝐴3 𝑥3 +. . . .
𝑥ҧ =
𝐴1 + 𝐴2 + 𝐴3 + …
𝑦1 + 𝑦2 + 𝑦3 +. .
𝑦ത =
𝑛
𝐹
Direct shear, 𝐹 ′ = 𝑛 Eqn 9.9(a)
Secondary shear proportional to the
radial distance from the centre of
gravity (assumption)
𝐹1 𝐹2 𝐹3
= = =⋯
𝑐1 𝑐2 𝑐3

Eqn 9.9(d)
𝐹𝑒𝑐 1
𝐹1′′ = 2
(𝑐1 + 𝑐22 + 𝑐32 + 𝑐42 )

Eqn 9.9(g)
𝐹𝑅 = 𝐹1′ + 𝐹1′′ + 2𝐹1′ 𝐹1′′ 𝑐𝑜𝑠𝜃

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 Problem 3.3
A steel plate subjected to a force of 5 kN and fixed to a channel
by means of three identical bolts is shown in Figure. The bolts
are made from plain carbon steel 45C8 (Syt = 380 N/mm2) and
the factor of safety is 3. Specify the size of bolts

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Eccentric load acting perpendicular to the axis of the bolt

𝐹
Direct shear, 𝐹 ′ = 𝑛 (Eqn 9.7a)
𝐹𝑒𝑙1
Secondary tensile, 𝐹1′′ = (Eqn 9.7b)
2(𝑙12 + 𝑙22 )
1
Equivalent tensile load, 𝐹𝑅 = 𝐹1′′ + 𝐹1′′2 + 4𝐹 ′2 (Eqn 9.7c)
2

1 ′2
Design bolt for
Equivalent shear load, 𝐹𝑅 = 𝐹1′′2 +𝐹 (Eqn 9.7d)
2 the total load
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 Problem 3.4
A wall bracket is attached to the wall by means of four identical
bolts, two at A and two at B as shown in Figure. Assuming the
bracket is held against the wall and prevented from tipping
about the point C by all four bolts and using an allowable
tensile stress = 35 N/mm2 , determine the size of the bolts on
the basis of maximum principal stress theory.

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Eccentric load acting parallel to the axis of the bolt

𝐹
Direct Tensile, 𝐹 ′ = 𝑛 (Eqn 9.7a)
′′
𝐹𝑒𝑙2
Secondary tensile, 𝐹1 = (Eqn 9.7b)
2(𝑙12 + 𝑙22 )
′ ′′
Total load, 𝐹𝑅 = 𝐹 + 𝐹1
Design bolt for the total load 𝐹𝑅
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 Problem 3.5
A crane runway bracket is fastened to the roof truss by means
of two identical bolts as shown in Figure. Determine the size
of the bolts, if the permissible tensile stress in the bolts is
limited to 75 N/mm2

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 Problem 3.6
Figure shows the bracket used in a jib crane to connect the tie
rod. The maximum force in the tie rod is 5 kN, which is
inclined at an angle 300 with horizontal. The bracket is
fastened by means of four identical bolts, two at A and two at
B. The bolts are made of plain carbon steel 30C8 (Syt = 400
N/mm2) and the factor of safety is 5. Assume maximum shear
stress theory and determine the size of the bolts.

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 Problem 3.7

A rigid bracket subjected to a vertical force of 10 kN is shown in Figure. It is

fastened to a vertical stanchion by means of four identical bolts. Determine the
size of the bolts by maximum shear stress theory. The maximum permissible
shear stress in any bolt is limited to 50 N/mm2

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Eccentric load acting perpendicular to the axis of the bolt

𝐹
Direct shear load, 𝐹 ′ = 𝑁 (Eqn 9.8a)
′′
𝐹𝑒𝑙1
Secondary tensile, 𝐹1 = 2 (Eqn 9.8b)
(𝑙1 + 𝑙22 + 𝑙32 + 𝑙42 )
𝑙1 = 𝑎 − 𝑏 cos θ 𝑙2 = 𝑎 + 𝑏 sin θ
Design bolt for
𝑙3 = 𝑎 + 𝑏 cos θ 𝑙4 = 𝑎 − 𝑏 sin θ
the total load
2𝐹𝑒(𝑎 − 𝑏𝑐𝑜𝑠𝜃) (Eqn 9.8c) 180
𝐹1−𝑛 = 𝑎 + 𝑏 cos( )
2𝑎2 + 𝑏 2 𝑁 𝑁
2𝐹𝑒(𝑎 + 𝑏) (Eqn 9.8d) 𝐹𝑚𝑎𝑥 = 2𝐹𝑒
2𝑎2 + 𝑏 2 𝑁
𝐹𝑚𝑎𝑥 = (Eqn 9.8e)
2𝑎2 + 𝑏 2 𝑁
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 Problem 3.8
A pillar crane, shown in
Figure is fastened to the
foundation by means of 16
identical bolts spaced
equally on 2 m pitch circle
diameter. The diameter of
the pillar flange is 2.25 m.
Determine the size of the
bolts if a load of 50 kN acts
at a radius of 7.5 m from the
axis of the crane. The
maximum permissible
tensile stress in the bolt is
limited to 75 N/mm2
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 Elastic analysis of bolted joints

Final load on the bolt 𝐹𝑏 =

𝐾𝐹𝑎 + 𝐹𝑖 (Eqn. 9.2a)

1
𝐾= 𝑘𝑔 (Eqn 9.2b)
1+𝑘
𝑏

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 Problem 3.9
Two circular plates with 2d and d as
outer and inner diameters
respectively, are clamped together by
means of a bolt as shown in Figure.
The bolts is made of plain carbon
steel 45C8 (Syt = 380 N/mm2 and E =
207000 N/mm2), while the plates are
made of aluminium (E = 71000
N/mm2). The initial pre load in the
bolt is 5 kN and the external force
acting on the bolted joint is 10 kN.
Determine the size of the bolt, if the
factor of safety is 2.5

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 Problem 3.10
The assembly of two circular plates
clamped together by means of a bolt
which is shown in Figure is subjected
to a variable force P varying from 0 to
10 kN. The bolts is made of plain
carbon steel 45C8 (Sut = 630 N/mm2,
Syt = 380 N/mm2 and E = 207000
N/mm2). The two circular plates are
made of aluminium (E = 71000
N/mm2). The fatigue stress
concentration factor is 2.2 and the
expected reliability is 90 %. The initial
pre load in the bolt is 5 kN.
Determine the size of the bolt if the
factor of safety is 2.
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Problem 3.10

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 Problem 3.11
Figure shows the arrangement of a supporting machine weighing 200 kg at a
distance of 1 m from the nearest point of support. The operation of the
machine creates a rotating unbalanced force of 2000 N in the plane of the
figure and at the position of the machine. The speed of rotation is 14 rpm.
The weight of the channel is 20 kg/m. Two bolts, denoted by 1 and 2, hold
the channel to the main frame. The bolts are located at 35 and 270 mm from
the nearest point of support. The following data is given for the bolts.
• Ultimate tensile strength = 960 MPa
• Yield point strength = 850 MPa
• Endurance limit in bending = 500 MPa
• Fatigue stress concentration factor = 3.0
• Factor of safety = 2
The initial preload in each bolt is 55 kN. The ratio of stiffness of the parts
held together by the bolts to the stiffness of the bolts is 3. Assume
Goodman line as the criterion of failure.
Determine the size of the bolts.

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Problem 3.11

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Problem 3.11

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 Problem 3.12
A round flange bearing as shown in Figure is fastened by means of
four cap screws spaced equally on 300 mm pitch circle diameter. The
diameter of the flange is 400 mm. The external force is 25 kN, which is
located at a distance of 150 mm from the machine frame. There are
two dowel pins to take shear load. The cap screws are relieved of all
shear force. Determine the size of the cap screws, if the maximum
permissible tensile stress in the cap screw is limited to 50 N/mm2.

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 Power Screws
Power screw is a mechanical device used for converting rotary
motion into linear motion and transmitting power.
Applications
• To raise the load
• To obtain accurate motion in machining
• To clamp a workpiece
• To load a specimen
Advantages
• Large load carrying capacity
• Compact construction
• Simple design
• Controlled and highly accurate linear motion
• Smooth and noiseless service
• Reduced cost and reliable
• Self locking property
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 Power Screws
Disadvantages
• Low efficiency
• High friction in threads
Forms of threads
• Square
• ISO metric trapezoidal

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 Threads: Comparison
Square Thread
Advantages Disadvantages
Efficiency is more Difficult to manufacture
No radial pressure or side Less thread thickness at core diameter
thrust
Screw or nut replacement due to wear
Trapezoidal Thread
Advantages Disadvantages
Manufactured on thread Efficiency is less
milling machine
More thickness at the core Side thrust or radial pressure on nut
diameter
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 Terminology in power screw
Definitions of pitch, lead, nominal diameter, core diameter follows
the same definition as seen in normal threaded joints

Helix angle (α)

Angle made by the helix
of the thread with a plane
perpendicular to the axis
of the screw
𝑑𝑐 = 𝑑1 = (𝑑 − 𝑝)
𝑑𝑚 = 𝑑2 = (𝑑 − 0.5𝑝)
𝑙 𝑙
tan 𝛼 = = 𝐸𝑞𝑛 9.10 𝑏
𝜋𝑑𝑚 𝜋𝑑2
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 Torque requirement: Lifting load

Equilibrium of vertical and horizontal components

𝐹𝑡 = 𝑓𝐹𝑛 𝑐𝑜𝑠𝛼 + 𝐹𝑛 𝑠𝑖𝑛𝛼
𝑊 = 𝐹𝑛 𝑐𝑜𝑠𝛼 − 𝑓𝐹𝑛 𝑠𝑖𝑛𝛼
Dividing the above equations and further arithmetic substitutions
𝑊(𝑓 + 𝑡𝑎𝑛𝛼)
𝐹𝑡 = Eqn 9.11a
(1 − 𝑓𝑡𝑎𝑛𝛼)
The effort Eqn 9.11a
The torque
𝐹𝑡 = 𝑊𝑡𝑎𝑛(∅ + 𝛼) 𝐹𝑡 𝑑2 Eqn 9.11b
𝑇=
2
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 Torque requirement: Lowering load

Equilibrium of vertical and horizontal components

𝐹𝑡 = 𝑓𝐹𝑛 𝑐𝑜𝑠𝛼 − 𝐹𝑛 𝑠𝑖𝑛𝛼
𝑊 = 𝐹𝑛 𝑐𝑜𝑠𝛼 + 𝑓𝐹𝑛 𝑠𝑖𝑛𝛼
Dividing the above equations and further arithmetic substitutions
𝑊(𝑓 − 𝑡𝑎𝑛𝛼)
𝐹𝑡 = Eqn 9.11d
(1 + 𝑓𝑡𝑎𝑛𝛼)
The effort The torque
𝐹𝑡 = 𝑊𝑡𝑎𝑛(∅ − 𝛼) Eqn 9.11d 𝐹𝑡 𝑑2 Eqn 9.11e
𝑇=
2
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 Self locking screw
The torque
𝐹𝑡 𝑑2 𝑊𝑑2 𝑡𝑎𝑛(∅ − 𝛼)
𝑇= =
2 2
If ∅ < 𝛼
Torque required to lower the load is negative
If ∅ ≥ 𝛼
Torque required to lower the load is positive (SELF LOCKING )
A screw will be self locking if the coefficient of friction is equal to or
greater than the tangent of the helix angle
𝑙
𝑓>
𝜋𝑑2
Causes of reduction in self locking property
• Lubrication
• High lead

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 Efficiency of square threaded screw
Work output=force X distance travelled in the direction of force=
𝑊𝑙
Work input = 𝐹𝑡 𝜋𝑑2
𝑊𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡 𝑊𝑙 𝑊
η= = = 𝑡𝑎𝑛𝛼
𝑊𝑜𝑟𝑘 𝑖𝑛𝑝𝑢𝑡 𝐹𝑡 𝜋𝑑2 𝐹𝑡
𝑡𝑎𝑛𝛼 𝑠𝑖𝑛𝛼/𝑐𝑜𝑠𝛼
η= =
𝑡𝑎𝑛 ∅ + 𝛼 𝑠𝑖𝑛 𝛼 + ∅ /𝑐𝑜𝑠 𝛼 + ∅

𝑠𝑖𝑛 2𝛼 + ∅ − 𝑠𝑖𝑛∅
η=
𝑠𝑖𝑛 2𝛼 + ∅ + 𝑠𝑖𝑛∅
For η to be maximum 𝑠𝑖𝑛 2𝛼 + ∅ should be maximum
𝑠𝑖𝑛 2𝛼 + ∅ =1 2𝛼 + ∅ = 90𝑜
1 − 𝑠𝑖𝑛∅
η=
1 + 𝑠𝑖𝑛∅
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 Efficiency of Self locking screw
𝑡𝑎𝑛𝛼
η= Eqn 9.11f
𝑡𝑎𝑛 ∅ + 𝛼
For a self locking screw
∅≥𝛼
Substituting limiting value
𝑡𝑎𝑛∅
η≤
𝑡𝑎𝑛 2∅
1 𝑡𝑎𝑛2 ∅
η≤ −
2 2
Maximum efficiency is less than ½ or 50%

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Collar friction torque

• Relative motion between cup and collar

induces Collar friction

• Torque required to overcome this collar

friction is obtained using uniform pressure or
uniform wear theory

• Normal force acting on collar: W

• Frictional force acting on collar: 𝑓𝑐 𝑊

• Zone of frictional force: 𝐷𝑚

𝑓𝑐 𝑊
• 𝑇𝑐 = (𝐷𝑚 ) Eqn 9.11g
2

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 Overall Efficiency

• The total external torque

𝑇𝑡 = 𝑇 + 𝑇𝑐

• Work output = Wl

• Work input: Torque X angle turned = 𝑇𝑡 2𝜋

𝑊𝑙
• Overall efficiency, η𝑜 =
2𝜋 𝑇 𝑡

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 Multiple threaded screw

𝑙=𝑝 𝑙 = 2𝑝 𝑙 = 3𝑝
• Double start or triple start screws
• Two or more threads cut side by side
• Large axial motion
• Efficiency high due to large helix angle
• Less mechanical advantage
• Self locking property may be lost
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 Problem 3.13
The nominal diameter of a triple threaded square screw is 50 mm,
while the pitch is 8 mm. It is used with a collar having an outer
diameter of 100 mm and inner diameter as 65 mm. The coefficient
of friction at the thread surface as well as at the collar surface can be
taken as 0.15. The screw is used to raise a load of 15 kN. Using the
uniform wear theory for collar friction. Calculate
• Torque required to raise the load
• Torque required to lower the load
• The force required to raise the load, if applied at a radius of 500
mm
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 Efficiency of Trapezoidal and ACME threads
Normal force on thread surface = 𝑊𝑠𝑒𝑐 𝛽

Effect of thread angle: To increase frictional force

Coefficient of friction : f sec β
Lifting load
𝑊(𝑓𝑠𝑒𝑐𝛽 + 𝑡𝑎𝑛𝛼) Eqn 9.10f
𝐹𝑡 =
(1 − 𝑓 sec 𝛽 𝑡𝑎𝑛𝛼)
Lowering load
𝑊(𝑓𝑠𝑒𝑐𝛽 − 𝑡𝑎𝑛𝛼) 𝐹𝑡 𝑑2
𝐹𝑡 = 𝑇=
(1 + 𝑓 sec 𝛽 𝑡𝑎𝑛𝛼) 2
Efficiency
𝑡𝑎𝑛𝛼(1 − 𝑓 sec 𝛽 tan 𝛼)
η= Eqn 9.10g
(𝑓 sec 𝛽 + tan 𝛼)

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Design of Screw and nut in Power Screw
Direct compressive stress and
torsional shear stress
𝑊 16𝑇
𝜎𝑐 = 𝜋 𝜏=
2
𝑑1 𝜋𝑑13
4
Maximum principal shear stress
𝜎𝑐 2
𝜏𝑚𝑎𝑥 = + 𝜏2
2
Transverse shear stress in the screw and
nut 𝑊 𝑊
𝜏𝑠 = 𝜏𝑛 =
𝜋𝑑1 𝑡𝑛 𝜋𝑑𝑡𝑛
Bearing pressure between screw and nut
4𝑊
𝑝𝑏 = 2 2 Eqn 9.13a
𝑛𝜋(𝑑 − 𝑑1 )
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Problem 3.14

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 Problem 3.14
The construction of a gate valve used in high pressure pipeline is shown in
Figure. The screw is rotated in its place by means of the handle. The nut is
fixed to the gate. When the screw rotates, the nut along with the gate moves
downward or upward depending upon the direction of rotation of the screw.
The screw has single start square threads of 40 mm outer diameter and 7
mm pitch. The weight of the gate is 5kN. The water pressure in the pipeline
induces frictional resistance between the gate and its seat. The resultant
frictional resistance in the axial direction is 2 kN. The inner and outer
diameters of thrust washer are 40 and 80 mm respectively. The values of
coefficient of friction at the threads and at the washer are 0.15 and 0.12,
respectively. The handle is rotated by the two arms, each exerting equal force
at a radius of 500 mm from the axis of the screw. Calculate
• The maximum force exerted by each arm when the gate is being raised
• The maximum force exerted by each arm when the gate is being lowered
• The efficiency of the gate mechanism
• The length of the nut, if the permissible bearing pressure is 5N/mm2

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 Problem 3.15
A single-start square threaded screw is used in a screw press to
exert a force of 50 kN. The screw is made of plain carbon steel 10C4
(Sut = 340 N/mm2) and the factor of safety is 4. The permissible
compressive stress is equal to permissible tensile stress and
permissible shear stress is 50% of permissible tensile stress. The nut
is made of grey cast iron FG200 and the permissible bearing
pressure between contacting surface of screw and nut is 17 MPa. A
low friction thrust ball bearing is used in the mechanism and collar
friction can be neglected. The coefficient of friction at the thread
surface between steel screw and cast iron nut can be taken as 0.15.
Determine the size of screw and nut. Check the transverse shear in
screw and nut. Axial length of thread in the nut. The axial length of
threads in the nut should be between 1 to 1.5 times of the nominal
diameter of screw.

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 Problem 3.16
It is required to design a double start
screw with square threads for the C
clamp shown in Figure. The maximum
force exerted by the clamp is 5kN. It is
assumed that the operator will exert a
force of 250 N at the ball handle of the
hand wheel. The screw is made of
plain carbon steel 45C8 (Syt=
330N/mm2), while the nut is made of
grey cast iron FG200. The dimensions
of the collar are given in Figure. The
factor of safety is 2. Determine the
dimensions of the screw and the nut
also calculate the radius Rm of the ball
handle. Assume permissible bearing
pressure =15 N/mm2
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Differential and Compound Screws
A differential screw is defined as
a mechanical device consisting
of two screws in series, which
are arranged in such a way that
the resultant motion is the
difference of individual motions
of two screws
𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑚𝑜𝑡𝑖𝑜𝑛 = 𝑝1 − 𝑝2

A compound screw is defined as a

mechanical device consisting of two
screws in series, which are arranged in
such a way that the resultant motion is the
sum of individual motions of two screws
𝑅𝑒𝑠𝑢𝑙𝑡𝑎𝑛𝑡 𝑚𝑜𝑡𝑖𝑜𝑛 = 𝑝1 + 𝑝2
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Differential and Compound Screws

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 Problem 3.17
A differential type of screw
jack is shown in Figure. In the
construction, the two screws
do not rotate and the nut is
rotated by the operator by
applying a force of 100 N at a
mean radius of 500 mm. The
coefficient of friction at the
threads is 0.15. Calculate
• The load that can be raised
• The efficiency of the screw
jack

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